Disposable hygienic and anti-allergenic pillow protector

ABSTRACT

A method of making a hygienic disposable pillow protector involves a step of folding a pillow protector material to define a first surface and a second surface, and to also define a closed end and an open end that is opposite the closed end. The pillow protector material is aligned to further define two unsealed edges. The method then involves sealing the unsealed edges of the pillow protector material by ultrasonic welding or bonding to define two sealed edges extending from the closed end to the open end to thereby define an opening sized to enable insertion of pillow into the disposable pillow protector. The method then involves applying a first strip of double-sided adhesive tape and applying a second strip of double-sided adhesive tape. A pillow may inserted into the disposable pillow protector and the opening sealed by forming folded seams with the first and second strips of tape.

TECHNICAL FIELD

The present invention relates generally to bedding and, more particularly, to pillow protectors.

BACKGROUND

Pillows used in households, hospitals, hotels, rental properties (e.g. Airbnb) and other public accommodation facilities can be a source of allergens and microbes (hereinafter referred to as ‘allergens’ or ‘contaminants’) that contribute or exacerbate pathologies such as allergies, asthma, chronic sinusitis, and other respiratory-related diseases.

It is not common practice to wash or frequently replace a used pillow, nor practical to regularly wash or sterilize a used pillow throughout its lifecycle. The most adoptable practice is to use a generic pillowcase (also known as a pillow protector or pillow cover) to encase a pillow as an effort to protect the pillow from contamination whenever it is being slept on. Periodically, the generic pillowcase is washed when it is soiled, becomes odorous, or used by patients in the hospitals or by guests in public accommodations. However, simply washing or changing to a clean generic pillowcase would not remove the pre-existing allergens and microbes that are inhabiting and growing inside a used pillow. Conventional pillow encasings are made from interwoven porous materials that contribute to creating an environment in which allergens accumulate. This material allows moisture from the ambient air or the sleeper's breath, saliva, dandruff and dead skin cells to permeate and accumulate in or on the pillow. Thus, it creates an environment which promotes the accumulation and growth of microbes and allergens such as dust-mites. Additionally, conventional pillowcases are open on one end, possess zippers, or alternative means of enclosure with innate gaps and/or punctures resultant from the sewing assembly process. These gaps or holes provide opportunities for contaminants to ingress and establish colonies in the pillow. Furthermore, dead skin cells that penetrate through and accumulate on the pillow surface can become a source of nourishment for the contaminants. In conjunction with the porous materials, conventional encasings allow for airborne contaminants to deposit the pillow or transfer of containments to freely pass between the user and the pillow.

Thus, a practical solution to prevent the user from contacting pre-existing contaminants found on pillows is desirable.

SUMMARY

In general, the present invention provides a disposable hygienic and anti-allergenic pillow protector that prevents the transfer of contaminants from the pillow to the user.

By employing a customized material and a reliably sealed encasing, the disposable pillow protector completely isolates the user from the pillow and thus minimizes the risk of contamination of allergen-producing entities and egression of allergens. To provide a protective barrier between the user from the pillow, the material must prevent moisture, contaminants, allergens, and skin sheds to pass through, yet remain breathable and comfortable to be slept on.

As described further below, the disposable pillow protector is made using three or more layers of spunbond non-woven filtration fabric that is water-impermeable, water-repellent, antimicrobial and breathable. The disposable pillow protector is fabricated with ultrasonic welding/bonding technology, thereby eliminating the holes from sewing needles. Thus, all seams of the disposable pillow protector are leakproof from allergens and moisture. The disposable pillow protector includes a compatible opening for a pillow to be inserted inside. The opening can be sealed with strips of double-sided adhesive tape covered with easy peel-off liners bonded to the opening, thus making it ready to use and seal after a pillow is inserted inside. This disposable pillow protector provides a sterile barrier around the pillow to prevent contamination and to minimize allergen egression.

Although this disposable pillow protector may be used for persons of any age, there is a clear need for such a product to protect vulnerable populations at risk of asthma, allergies, and other respiratory diseases. Such a product can be used as a pillow protector or as a protective layer between a generic pillowcase and a pillow. The opening closure function is intended for single-use that allows for easy encasing of a pillow. This affordable single-use disposable pillow protector facilitates personal hygiene and minimizes interacting with pre-existing microbes and allergens on pillows. This single-use disposable pillow protector effective minimizes the chance of transmitting respiratory infective diseases amongst users sleeping on shared pillows, especially those pillows that are provided by public accommodation facilities such as hotels.

An inventive aspect of the disclosure is a method of making a hygienic disposable pillow protector involves a step of folding a pillow protector material to define a first surface and a second surface, and to also define a closed end and an open end that is opposite the closed end. The pillow protector material is aligned to further define two unsealed edges. The method then involves sealing the unsealed edges of the pillow protector material by ultrasonic welding or bonding to define two sealed edges extending from the closed end to the open end to thereby define an opening sized to enable insertion of pillow into the disposable pillow protector. The method then involves applying a first strip of double-sided adhesive tape and applying a second strip of double-sided adhesive tape. A pillow may inserted into the disposable pillow protector and the opening sealed by forming folded seams with the first and second strips of tape.

Another inventive aspect of the disclosure is a disposable pillow protector comprising a pillow protector material folded to define a first surface and a second surface, and to also define a closed end and an open end that is opposite the closed end, the pillow protector material being aligned to further define two unsealed edges. The disposable pillow protector comprises two sealed edges that are sealed by ultrasonic welding or bonding and that extend from the closed end to the open end to thereby define an opening sized to enable insertion of pillow into the disposable pillow protector. The disposable pillow protector also includes a first strip of double-sided adhesive tape and a second strip of double-sided adhesive tape.

The foregoing presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the invention. It is not intended to identify essential, key or critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later. Other aspects of the invention are described below in relation to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present technology will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

FIG. 1A is a rear view of a disposable pillow protector material that is folded up with the user-side on the outside as a first step of manufacturing the disposable pillow protector in accordance with an embodiment of the present invention.

FIG. 1B is a perspective view of the disposable pillow protector material shown in FIG. 1A.

FIG. 2 is a rear view illustrating that both side seams are sealed by ultrasonic welding/bonding technology leaving an opening accessible at the top to insert a pillow.

FIG. 3 is a rear view illustrating the completed pillow protector with two strips of double-sided adhesive tape covered with easy peel-off liners bonded to the designated locations at the opening of the disposable pillow protector material.

FIG. 4 is a rear view illustrating the unsealed disposable pillow protector with a pillow inserted through the unsealed opening prior to sealing the opening of the disposable pillow protector.

FIG. 5 is a rear view illustrating that a sealed disposable pillow protector with a pillow encased inside that is sealed by folding the upper strip of double-sided adhesive tape to seal the opening.

FIG. 6 is rear view illustrating the disposable pillow protector with a pillow inside in which the upper folded seam of the disposable pillow protector is further folded down to be precisely adhered on top of the lower strip of double-sided adhesive tape to doubly seal the opening.

FIG. 7 is a front view illustrating the sealed disposable pillow protector with a pillow sealed inside.

It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

DETAILED DESCRIPTION

In general, and as will be described in greater detail below, a first aspect of the present invention is a method of making a single-use disposable hygienic and anti-allergenic pillow protector (hereinafter referred as a “disposable pillow protector”). In the embodiment depicted in the figures, the disposable pillow protector is composed of three or more layers of spunbond non-woven filtration fabric or equivalent material. Instead of conventional sewing with needles and thread, the disposable pillow protector is fabricated, in the illustrated embodiment, by ultrasonic welding/bonding technology. The opening can be sealed with double-sided adhesive tape or multiple strips of such tape. Together, these components constitute an integrated leak-proof barrier to encase a pillow, which effectively prevent or at least mitigates the transmission of allergens and microbes between the sleeper and pillow. The beneficial properties of the completed disposable pillow protector are substantiated by American PPE testing standard ANSI/AAMI PB70 (level 2 or higher) although it will be appreciated that the novel method and the disposable pillow protector produced by this method are not limited to this testing standard. Any other compatible industrially recognized testing methods and standards may be employed to substantiate the anti-allergenic properties of the disposable pillow protector.

Reference will be made to the embodiment depicted in the figures. In addition to the drawings, this description discloses other embodiments beyond the drawings. Accordingly, there is no intent to limit the invention to a single embodiment or embodiments that are disclosed herein. The intent is to cover all alternatives, modifications, and equivalents within the scope of this disclosure as defined by the appended claims.

FIGS. 1A and 1B illustrate a first step in a method of making a disposable pillow protector designated by reference numeral 10 in accordance with an embodiment of the present invention. In this first step of the method, a disposable pillow protector material 12 is folded and aligned as shown for the next step of the fabrication method. In this embodiment, the disposable pillow protector material 12 has a generally elongated rectangular shape. The disposable pillow protector can be made to fit standard or customized pillow sizes.

The disposable pillow protector material 12 has an inside pillow protector backing layer 14. The disposable pillow protector 12 is folded to define a first surface 11 and a second surface 13. As shown in these figures, the second surface 13 extends beyond the first surface at the opening. In other words, the second surface 13 has an upper protruded margin 15 that is provided as the designated space for a strip of double-sided adhesive tape to be bonded as will be explained below. The width of the margin can be made compatible with the intended width of the double-sided adhesive tape. The underlying material is aligned to protrude at the opposite of the fold (the opening) by a margin of 2 cm, for example, although another size of margin may be used to match a width of any particular double-sided adhesive tape being used. FIG. 1B also shows that the folding of the pillow protector material 12 defines a closed end 17 and an open end that is opposite the closed end. The open end, once the unsealed edges are sealed, defines an opening 16 of the pillow protector. By folding and aligning the pillow protector material as shown in FIGS. 1A and 1B, two unsealed edges are defined.

FIG. 2 shows the result of the next step of the method in which ultrasonic welding/bonding technology is used to securely bond and seal both edges to render them waterproof and allergen proof. Sealing of the edges can be achieved with an alternative method to render the disposable pillow protector waterproof and allergen proof. As shown in FIG. 2, this step of sealing the edges creates an opening 16 and two sealed edges 18.

FIG. 3 shows the result of the subsequent step of applying two strips of industrial grade double-sided adhesive tape that are covered with easy peel-off liners. In this embodiment, the upper strip 20 and lower strip 22 are parallel and spaced apart by a gap between the strips. The gap between the strips 20, 22 may be greater than the thickness of each individual strip as shown in this figure or another spacing may be used. The upper strip 20 may be placed along the edge of the opening 16 as shown although in another embodiment it may be spaced from the opening. These strips are bonded to the designated upper edges of the disposable pillow protector material, making it ready for immediate use after a pillow is inserted inside. This ready leak-proof closure is easy for users to seal the opening with a simple D-I-Y (Do-It-Yourself) fold down process. This sealing of the opening is achievable with alternative methodologies. FIG. 3 also illustrates the completed disposable pillow protector that is ready to be used by a user.

FIG. 4 the disposable pillow protector after a pillow has been inserted inside the disposable pillow protector via the opening 16. As shown in this figure, the easy peel-off liners are in place to prevent the double-sided adhesive tape strips 20, 22 from contamination.

FIG. 5 illustrates the disposable pillow protector with the pillow inside after the upper strip of double-sided adhesive tape has been folded down (with the liner peeled off) and the opening is sealed. It is noted that the pillow is inserted into the pillow protector before the upper strip 20 of double-sided adhesive tape is folded down. The folding of the upper strip 20 creates an upper folded seam 24 (also referred to herein as a first folded seam as will be explained below). Since the double-sided adhesive tape is intended for single-used only, the sealed disposable pillow protector should not be reopened until it needs to be disposed.

FIG. 6 illustrates the formation of a second folded seam by further folding the first folded seam onto the lower strip 22. The first folded seam 24 is precisely adhered on top of the lower strip 22 of double-sided adhesive tape (with the liner peeled off) to further secure (i.e. doubly seal) the pillow encased inside. Since the double-sided adhesive tape is intended for single-used only, the sealed disposable pillow protector should not be reopened until it needs to be disposed.

FIG. 7 illustrates the front-side of the disposable pillow protector that does not have any folded seam for sealing the opening, so the front-side is the preferred surface to be slept on. Since the double-sided adhesive tapes are intended for single-used only, the sealed disposable pillow protector should not be reopened until it needs to be disposed.

From the foregoing description, various innovative features and aspects become apparent. Pre-forming of the disposable pillow protector by applying ultrasonic welding/bonding methodology (instead of needle-based sewing) seals all the seams adjacent to the fold of the pillow to render it waterproof and allergen-proof. This method does may be performed using an alternative seam sealing technique that does not puncture the material and thus preserves its protective barrier against allergens and moisture.

The application of built-in industrial grade double-sided adhesive tapes enables the closure using a simple D-I-Y process for a user to seal the opening easily after a pillow is encased inside. This method of securing the encased pillow and rendering it waterproof and allergen-proof may be achieved using any alternative methods for D-I-Y closure that fully seal the opening to ensure that no moisture or allergens ingress or egress. This ready-made closure, which helps maintain personal hygiene, enables the fabrication of a versatile and cost-effective single-use, disposable pillow protector.

In one embodiment, the disposable pillow protector material is composed of three or more layers of spunbond non-woven fabric designed or engineered to be water-impermeable, water-repellent, and air-permeable. The composite of this spunbond non-woven filtration fabric can be customized with suitable combinations of polyurethane-based, polyethylene-based, and polytetrafluoroethylene-based membrane with micropores, but not limited to other alternative composites of compatible properties. Thus, the disposable pillow protector made of the above mentioned spunbond non-woven fabric provides the desired hygienic properties.

The method described herein enables a disposable pillow protector to be made that avoids conventional sewing with thread and needle which causes numerous punctures and gaps. Due to the novel method of making this disposable pillow protector, it is impenetrable to moisture, water, and contaminants. Thus, it minimizes allergens, contaminants, moisture, and microbes passing from the encased pillow to the user. By minimizing egress of contaminants and allergens from the encased pillow, the user is protected from exposures that can exacerbate respiratory or dermal medical conditions.

Similarly, the disposable pillow protector minimizes the ingress of contaminants, bacteria, food sources, and moisture from the user and environment to the encased pillow. This minimizes the formation or maintenance of an environment that sustains organisms such as bacteria, bedbugs, dust mites, and other microbes.

For the purposes of interpreting this specification, when referring to elements of various embodiments of the present invention, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, “having”, “entailing” and “involving”, and verb tense variants thereof, are intended to be inclusive and open-ended by which it is meant that there may be additional elements other than the listed elements.

This new technology has been described in terms of specific implementations and configurations which are intended to be exemplary only. Persons of ordinary skill in the art will appreciate that many obvious variations, refinements and modifications may be made without departing from the inventive concepts presented in this application. The scope of the exclusive right sought by the Applicant(s) is therefore intended to be limited solely by the appended claims. 

1. A method of making a hygienic disposable pillow protector, the method comprising: folding a pillow protector material to define a first surface and a second surface, and to also define a closed end and an open end that is opposite the closed end, the pillow protector material being aligned to further define two unsealed edges; sealing the unsealed edges of the pillow protector material by ultrasonic welding or bonding to define two sealed edges extending from the closed end to the open end to thereby define an opening sized to enable insertion of pillow into the disposable pillow protector; applying a first strip of double-sided adhesive tape; and applying a second strip of double-sided adhesive tape.
 2. The method of claim 1 wherein the second surface extends beyond the first surface at the open end by a margin, and wherein the first strip of double-sided adhesive tape is applied to the margin.
 3. The method of claim 2 wherein applying the second strip of double-sided adhesive tape comprises spacing the second strip of double-sided adhesive tape apart from the first strip of double-sided adhesive tape.
 4. The method of claim 1 wherein the pillow protector material is composed of three or more layers of spunbond non-woven filtration fabric.
 5. The method of claim 4 wherein the fabric is water-impermeable, water-repellent, antimicrobial and breathable.
 6. The method of claim 1 further comprising inserting a pillow through the opening.
 7. The method of claim 6 further comprising folding the first strip of double-sided adhesive tape onto the first surface to create a sealed folded seam.
 8. The method of claim 7 further comprising folding the sealed folded seam a second time onto the second strip of double-sided adhesive tape to doubly seal the opening of the disposable pillow protector.
 9. A disposable pillow protector comprising: a pillow protector material folded to define a first surface and a second surface, and to also define a closed end and an open end that is opposite the closed end, the pillow protector material being aligned to further define two unsealed edges; two sealed edges that are sealed by ultrasonic welding or bonding and that extend from the closed end to the open end to thereby define an opening sized to enable insertion of pillow into the disposable pillow protector; a first strip of double-sided adhesive tape; and a second strip of double-sided adhesive tape.
 10. The disposable pillow protector of claim 9 wherein the second surface extends beyond the first surface at the open end by a margin, and wherein the first strip of double-sided adhesive tape is applied to the margin.
 11. The disposable pillow protector of claim 10 wherein the second strip of double-sided adhesive tape is spaced apart from the first strip of double-sided adhesive tape.
 12. The disposable pillow protector of claim 9 wherein the pillow protector material is composed of three or more layers of spunbond non-woven filtration fabric.
 13. The disposable pillow protector of claim 12 wherein the fabric is water-impermeable, water-repellent, antimicrobial and breathable. 